installation instructions

installation instructions
89501 Rev B
INSTALLATION INSTRUCTIONS
For Rancho Suspension Systems:
RS66501B – 6”
2015 Ford F150 4WD
— FMVSS 126 Certified —
Fits OE 18” and up rims and spare
ONLY WITH OE TIRES
Shown & Tested with:
BFGoodrich All-Terrain T/A KO2 35X12.50R18LT Tires
Vision Manx 18 x 9 +18 Offset (5.6” Backspacing) Wheel
WARNING
Carefully read, understand and follow the instructions provided in this manual, and keep it in a safe place for future
reference. If you have any doubt whatsoever regarding the installation or maintenance of your Rancho suspension
system, please see your retailer for assistance or advice. Failure to follow the warnings and instructions provided
herein can result in the failure of the suspension system, or can cause you to lose control of your vehicle, resulting
in an accident, severe personal injury or death.
These instructions should remain in the vehicle glove box for future reference.
Rancho Suspension
89501 Rev B
2) Your brake lines and fuel lines should remain undisturbed
during and after installation. If you think you need to modify
these components in any way, you are mistaken. You are
installing the lift improperly and will be creating a significant
risk of an accident. In case of any doubt, consult a qualified
mechanic.
WARNING:
READ ALL INSTRUCTIONS
THOROUGHLY FROM START TO FINISH BEFORE
BEGINNING INSTALLATION. Failure to follow the
warnings and instructions provided herein can result
in an accident, severe personal injury or death.
PRELIMINARY
3) If any component does not fit properly, something is
wrong. You are installing the lift kit improperly and will be
creating a significant risk of an accident. Never modify any
component of the vehicle or suspension system, except as
instructed herein. Do not continue with installation until you
have identified the problem.
This manual presumes that all persons installing this suspension
system have a high level of mechanical training and experience,
and have available to them all necessary tools and safety
equipment. This manual is not and should not be construed as an
exhaustive list of all required safety measures. Personnel should
rely primarily on their training and experience, as well as on their
own common sense.
4) Several of the procedures described herein require at
least two (2) persons to safely complete the task. If you have
any doubt about your ability to complete any operation by
yourself, always ask for help from a qualified assistant.
This Manual is to be read as a supplement to, and must not be
construed as a substitute for, the owner’s manual and/or shop
manual that originally accompanied the vehicle. Refer to such
use, operation, maintenance and safety manuals as necessary,
and especially after installation is complete, to insure proper
vehicle operation.
5) Before starting any operation, confirm that all personal
safety devices and safety equipment are in proper condition
and position.
6) Give your work undivided attention. Looking around,
carrying on a conversation and "horse-play" are careless acts
that can result in an error in installation and/or serious injury.
The following terminology has been used in this Manual:
I.
ACCIDENT:
Any event which could cause
personal injury or death to anyone installing or
using the suspension
system, as well as
to passengers and bystanders, or otherwise
may result in property damage.
7) Install only tires approved by the United States
Department of Transportation (“DOT approved”). Make sure
the rim and tire size are properly matched.
PRE-INSTALLATION WARNINGS and
INSTRUCTIONS
8) If any components of the vehicle or suspension system
are damaged in any way during installation, immediately
replace the component.
WARNING: Only the following rim/tire sizes
may be used with this suspension system:
35X12.50R18LT tires 18X9 +18 offset (5.6” Backspacing) wheel.
9) During installation, carefully inspect all parts of the
vehicle and replace anything that is worn or damaged.
10) Nip points present the risk of the catching, lacerating,
crushing and/or amputating fingers, hands, limbs and other
body parts during operations. Always keep clear. Wear
protective gloves.
Use of any other rim/tire combination increases the
risk of a roll-over and/or accident, resulting in severe
personal injury or death.
11) Oil and hydraulic fluids are poisonous, dangerous to
health and are known to the State of California to cause
cancer, birth defects or other reproductive harm. Do not inhale
vapors or swallow. Do not allow contact with the eyes or skin.
Should any oil or fluids be swallowed or inhaled or come into
contact with the eyes, immediately follow the safety
precautions on the label or call a poison control center
immediately. Should any of the oil or fluids contact your skin,
immediately wash thoroughly.
WARNING:
This suspension system will
enhance the off-road performance of your vehicle. It
will handle differently; both on and off-road, from a
factory equipped passenger car or truck. Failure to
drive this vehicle safely may result in serious injury
or death to the driver and passengers. ALWAYS
WEAR your seat belts, REDUCE your speed, and
AVOID sharp turns and other abrupt maneuvers.
12) Never install the suspension system if you are under the
effects of alcohol, medications and/or drugs. If you are taking
prescription or over the counter medication, you must consult a
medical professional regarding any side effects of the
medication that could hinder your ability to work safely.
1) Service and repair tasks require specialized knowledge,
training, tools, and experience. General mechanical aptitude may
not be sufficient to properly install this suspension system. If you
have any doubt whatsoever regarding your ability to properly
install the suspension system, please consult a qualified mechanic
2
WARNINGS AND INSTRUCTIONS AFTER
INSTALLATION
New front Rancho shock absorbers are required and must be
purchased separately.
Front
13) After installation is complete, drive the vehicle slowly in
an area free from heavy traffic for at least three (3) miles.
Likewise, before traveling on any highways or at a high rate of
speed, drive the vehicle for ten (10) miles on side roads at
moderate speed. If you hear any strange noise or feel unusual
vibration, if a component of the suspension system is not
operating properly, or if any warning lights illuminate or
buzzers sound, stop the vehicle immediately. Identify the
cause and take any necessary remedial action.
Spacer Kit
RS886520
Rear
RS999287
RS7287
RS5287
Front shocks to be available in fall of 2015
C.
Do not powder-coat or plate any of the components in this
system. To change the appearance of components, automotive
paint can be applied over the original coating.
D.
Each hardware kit in this system contains fasteners of high
strength and specific size. Do not mix hardware kits or substitute a
fastener of lesser strength. See bolt identification table on page 4.
14) Confirm that all components of the vehicle, including all
lights (headlights, turn signals, brake lights, etc.), linkages
(accelerator, etc.), electrical switches and controls (windshield
wipers and defoggers, etc.), and other warning devices (low
tire pressure monitoring systems) are fully operational.
E.
Compare the contents of this system with the parts list in
these instructions. If any parts are missing, contact the Rancho
Technical Department at 1-734-384-7804.
F.
Install all nuts and bolts with a flat washer. When both SAE
(small OD) and USS (large OD) washers are used in a fastener
assembly, place the USS washer against the slotted hole and the
SAE washer against the round hole.
15) Your headlights will need to be readjusted before the
vehicle is used on the roads. Consult the vehicle owners’
manual.
G.
Apply a drop of thread locking compound to all bolts during
installation.
CAUTION: Thread locking compound may irritate
sensitive skin. Read warning label on container before use.
16) The speedometer and odometer will need to be
recalibrated after installation. See your dealer.
17) Confirm proper rear view and side view while seated in
the driver seat. Install supplemental mirrors as necessary.
H.
Unless otherwise specified, tighten all nuts and bolts to the
standard torque specifications shown in the table on page 2. USE A
TORQUE WRENCH for accurate measurements.
18) Your original low tire pressure monitoring system may be
re-installed in your new wheels. However, if you choose to
purchase a new system, see your dealer to have them properly
calibrated. Proper tire pressure is critical to safe operation of
the vehicle.
I.
Some of the service procedures require the use of special
tools designed for specific procedures. The following tools and
supplies are recommended for proper installation of this system: If
you do not know how to safely use any of these tools, stop the
project and consult a qualified mechanic.
OPERATION


















19) Because it has been modified, the vehicle will not handle,
turn, accelerate or stop in the same manner as an unmodified
vehicle. In addition, the crash protection systems designed in
the vehicle may operate differently from an unmodified vehicle.
For example, turning and evasive maneuvers must be
executed at a slower rate of speed. Further, there is a greater
risk that the vehicle could roll over. These differences could
result in an increased possibility of an accident, personal injury
or death. Learn the vehicle’s operations and handling
characterizes and drive accordantly.
IMPORTANT NOTES
A.
Before installing this system, have the vehicle’s alignment
and frame checked by a certified technician. The alignment must be
within factory specifications and the frame of the vehicle must be
sound (no cracks, damage or corrosion).
B.
The components of Rancho’s suspension system are
designed as a single integrated system. To avoid compromises in
terms of safety, performance, durability or function, do not substitute
Rancho components with components manufactured by other
companies. Use of other components will result in the forfeiture of
any type of warranty on the vehicle/suspension system.
3
Ford Service Manual
Die Grinder with cut-off blade or Sawzall
Vacuum Cap
Coil Spring Compressor
Torque Wrench (260 FT-LB capacity)
Ford Ball Joint Tool- part number- 204-592
1/2” Drive Ratchet and Sockets
Assorted Combination Wrenches
Heavy Duty Jack Stands
Wheel Chocks (wooden blocks)
Hydraulic Floor Jack
File
Hammer
Wire Brush (to clean bracket mounting surfaces)
Black Enamel Paint
Silicone Spray Lubricant
Tape Measure
Safety Glasses (wear safety glasses at all times)
J.
It is extremely important to replace coil springs, CV flanges,
and front drive shaft/pinion relationships as original. Be sure to mark
left/right, front/rear, and indexing of mating parts before disassembly.
A paint marker or light colored nail polish is handy for this.
N.
Important information for the end user is contained in the
consumer/installer information pack. If you are installing this system
for someone else, place the information pack on the driver’s seat.
Please include the installation instructions when you finish.
K.
Suspension components that use rubber or urethane
bushings should be tightened with the vehicle at normal ride height.
This will prevent premature failure of the bushing and maintain ride
comfort.
O.
The lifespan of Rancho products depends on many factors.
Improper use, abuse or harsh use in general may compromise the
integrity of the suspension system and significantly reduce its
lifespan. The suspension system is also subject to wear over time.
Have the suspension system regularly inspected and maintained by
qualified mechanics. If the inspection reveals any damage or
excessive wear, no matter how slight, immediately replace or repair
the component. The suspension system must be regularly
maintained in order to optimize its safe and efficient use. The more
severe the conditions under which the suspension system is
operated, the more often it must be inspected and maintained.
L.
The required installation time for this system is
approximately 5 to 6 hours. Check off the box () at the beginning
of each step when you finish it. Then when you stop during the
installation, it will be easier to find where you need to continue from.
M.
This suspension system was developed and tested using
the following tire & wheel combination:
BFGoodrich All-Terrain T/A KO2 35X12.50R18LT Tires with Vision
Manx 18 x 9 +18 Offset (5.6” Backspacing) Wheel.
Before installing any other combination, consult your local tire and
wheel specialist.
STANDARD BOLT TORQUE & IDENTIFICATION
Bolt Size
5/16
3/8
7/16
1/2
9/16
5/8
3/4
INCH SYSTEM
Grade 5
15 FT-LB
30 FT-LB
45 FT-LB
65 FT-LB
95 FT-LB
135 FT-LB
185 FT-LB
Grade 8
20 FT-LB
35 FT-LB
60 FT-LB
90 FT-LB
130 FT-LB
175 FT-LB
280 FT-LB
Bolt Size
M6
M8
M10
M12
M14
M16
M18
METRIC SYSTEM
Class 9.8
Class 10.9
5 FT-LB
9 FT-LB
18 FT-LB
23 FT-LB
32 FT-LB
45 FT-LB
55 FT-LB
75 FT-LB
85 FT-LB
120 FT-LB
130 FT-LB
165 FT-LB
170 FT-LB
240 FT-LB
Class 12.9
12 FT-LB
27 FT-LB
50 FT-LB
90 FT-LB
145 FT-LB
210 FT-LB
290 FT-LB
The driver of this suspension system recognizes and agrees that there are risks inherent in driving a vehicle with a lifted
suspension system, including but not limited to the risk that you could be involved in an accident that would not occur in an
unmodified vehicle. By his/her purchase and use of this suspension system, the user expressly, voluntarily and knowingly
accepts and assumes these risks, and agrees to hold Tenneco, Inc. and its related companies harmless to the fullest extent
permitted by law against any resulting damages.
4
Box 1 of 4
Box 2 of 4
2
1
ITEM
2
PART #
DESCRIPTION
QTY
RS66501B-2
RS176743
Box 2 Of 4
Knuckle - Left 6"
1
1
Box 3 of 4
ITEM
1
PART #
DESCRIPTION
RS66501B-1
RS176742B
Box 1 Of 4
Subframe
QTY
3
1
1
ITEM
3
Box 4 of 4
16
0
16
11
10
1
0
10
17
17
13
0
10
18
8
18
6
15
9
6
9
12
5
5
4
11
0
12
13
4
7
4
5
6
7
8
9
14
16
16
ITEM
DESCRIPTION
RS66501B-3
RS176744
Box 3 Of 4
Knuckle - Right 6"
QTY
1
1
Sub Assy, Brake line Bracket
HHCS, M8-1.25X20Mm
Nut, M8-1.25 Nylock
Washer, M8
Wire Tie 10 pack
U-Bolt, 9/16-18X3.16X12
Sub Assy, 9/16 U-Bolt
Washer, 9/16 X 3/16 Thick
Nut, 9/16-18 Nylock
Winged Riser Block
Sub Assy, Rear Brake
Parking Brake Cable Drop
Rear Brake Hose Drop
Washer, M8
Nut, M8-1.25 Nylock
HHCS, M8-1.25X20Mm
Sub Assy, Rear Drive Shaft
Rear Drive Shaft Spacer
Sub Assy, Spacer Hardware
HHCS, M12-1.75X70MM
Washer, M12
Sub Assy, Vent Hose
Tube Fitting
Rubber Tube
Instructions RS66501B
Information Pack
Aft Brace Bracket
Aft Brace
Sub Assy, Fwd Bracket
HHCS, 1/2-13 X 1.00
Nut 1/2-13 Stover
Washer, 1/2 SAE
Sub Assy, Aft Brace
Sleeve, .750 X .09
Bushing
HHCS, 1/2-13 X 4.0
HHCS, 1/2-13 X 1.0
Nut 1/2-13 Stover
Washer, 1/2 SAE
Nut Bracket
Thread Lock
Leaf Spacer .250"
1
2
2
4
1
4
1
8
8
2
1
1
1
5
3
2
1
1
1
4
4
1
1
1
1
1
4
2
1
2
2
4
1
4
8
4
2
4
10
2
1
2
Box 4 of 4 Continued
14
11
PART #
PART #
DESCRIPTION
RS66501B-4
RS176745B
RS860783
RS770041
RS7877
RS770109
RS860784
RS176311
RS770123
RS770118
RS176746B
RS860506
RS770080
RS7657
RS770064
RS176747B
RS176586
RS860785
RS770256
RS770230
RS42702
RS176780
Box 4 Of 4
Diff Drop Bracket
Sub Assy, Diff Drop
HHCS, M14-2.00X90MM
Nut, M14-2.00 Toplock
Washer, M14
Sub Assy, Alignment Bolt
Cam Bolt
Washer, M18
Nut, M18 X 2.5 Nylock
Sway Bar Drop Brkt
Sub Assy, Front M10
HHCS, M10-1.50X30MM
Nut, M10-1.50 Nylock
Washer, M10
Skid Plate
Front Driveshaft Spacer
Sub Assy, Driveshaft Spacer
12 Pt M10-1.5 Class 12
Washer, M10 18Mm Od
Thread Lock
Front Brake Line Bracket
QTY
1
2
1
3
3
6
1
4
4
4
2
2
4
4
8
1
1
1
6
6
1
2
15
16
17
18
5
RS860786
RS770127
RS603112
RS770128
RS1900-12
RS740017
RS860152
RS770062
RS7737
RS15104
RS860787
RS176748
RS176314
RS770128
RS603112
RS770127
RS860731
RS176691
RS860732
RS77035
RS7915
RS860749
RS96327
RS96328
RS89501
RS94180
RS176160B
RS176222B
RS860789
RS603605
RS78361
RS7723
RS860474
RS420072
RS520041
RS603616
RS603605
RS78361
RS7723
RS176137
RS42702
RS176749
RS886520
ITEM
19
19
6
PART #
DESCRIPTION
RS176750B
RS860746
RS770260
RS7726
RS88519-2
Shock Spacer-6”
Sub Assy, Shock Spacer
Nut, 7/16-20 Nylock
Washer, 7/16 SAE
Instructions, RS886520
QTY
2
1
6
6
1
Upper Control Arm
Upper Shock Mount
Steering Knuckle
Steering Knuckle
Upper Control Arm
Caliper
Axle Nut
Sway Bar
Lower Control Arm
Rotor
Caliper
Lower Shock Mount
Rotor
Lower Control Arm
Tie Rod End
Illustration 1
Illustration 2
FRONT SUSPENSION
VEHICLE PREPARATION & SWAY BAR REMOVAL
1)  Park the vehicle on a level surface. Set the parking
brake and chock rear wheels. Measure and record the
distance from the center of each wheel to the top of the fender
opening. See Illustration 3. Record these measurements in
the space provided below.
Illustration 4
Illustration 3
2)  Raise the front of the vehicle and support the frame
with jack stands. Remove the front wheels and set them aside.
3)  If applicable, remove the front splash shields and / or
skid plates. Remove splash shield brackets from side of frame
rails. See Illustration 4 and Illustration 5.
Illustration 5
4)  Hold the hex stud and remove the nut attaching the
sway bar end link to the sway bar. See Illustration 2 and
Illustration 6. Repeat for other side.
7
Illustration 6
5)  Remove the four nuts holding the sway bar to the
frame. Remove the sway bar assembly. See Illustration 6.
STEERING KNUCKLE, SHOCK & LOWER CONTROL ARM REMOVAL
1)  Separate the ABS wire from brake hose. Separate
plastic clips holding vacuum line and ABS wire from brackets
and frame. Remove brackets from frame and steering knuckle.
Separate metal brake line from plastic clip in frame. separate
vacuum line from steering knuckle. See Illustration 7.
Illustration 8
WARNING: Do not hammer the ball studs to
separate them from components. You could damage
the ball studs, without this damage being visible to
you, resulting in sudden and unexpected failure of
the ball studs and an accident.
Separate
Separate
ABS Wire
Remove
Brackets
Separate
6)  Mark position of alignment cams (if equipped) and
loosen all four lower control arm pivot bolts.
Remove
Bracket
Separate
7)  Remove the nut from the outer tie rod stud. Using
Ford Service tool #204-592 separate tie rod end stud from
knuckle. Loosely re-install to keep steering knuckle from
turning. See Illustration 1.
Steering Knuckle
Brake Hose
Vacuum Line
Remove
Illustration 7
8)  Loosen the nuts at the upper and lower ball joints.
Using Ford Service tool #204-592 separate ball joints from
knuckle.
2)  Remove the brake caliper anchor bolts. See
Illustration 8. Remove the brake caliper and its mounting
bracket as an assembly. Hang the caliper assembly with wire
or a tie wrap.
9)  Remove the upper and lower ball joint nuts. Carefully
remove the steering knuckle. Cover the exposed hub to
prevent contamination.
WARNING: Do not allow the caliper to hang by
the brake hose. You could damage the hose, without
this damage being visible to you, resulting in sudden
and unexpected brake failure and an accident.
10)  Loosen the three shock absorber upper mount to
frame nuts. See Illustration 9
11)  Remove the shock absorber lower mounting nuts and
swing lower control arm down off the shock studs.
3)  Label the brake rotor left or right. Remove the brake
rotor.
12)  Remove the three shock absorber upper mount to
frame nuts. Remove the shock absorber and spring assembly.
4)  Remove the dust shield. Disconnect the ABS sensor
from the wheel hub. See Illustration 8.
13)  Remove the lower control arm pivot bolts. Remove the
lower control arm. See Illustration 9.
5)  Remove the axle cap using a small chisel and
hammer to pry off. Remove axle nut. See Illustration 8.
8
Note: A plastic shield covering the steering rack may need to
be removed to access bolt. This shield is fastened to the frame
with two plastic clips. See Illustration 11. Shield shown
removed. Shield fits in same position, but inside of frame rail.
Upper Mount
Lower Mount
Illustration 9
FRONT DIFFERENTIAL REMOVAL
1)  Remove the four bolts that attach the cross-member
to the lower control arm pockets. Remove the cross-member.
See Illustration 10.
Drive Shaft
Illustration 11
9)
 Remove the differential assembly from the vehicle.
Transmission Lines
Passenger
Driver
Vent
Cross-member
Diff Aft. Mount
Aft
Diff Pass. Mount
Illustration 12
Illustration 10
FRONT DIFFERENTIAL & SUBFRAME INSTALLATION
2)  Index-mark the front driveshaft flange to the front
differential pinion flange.
Box RS66501B-1 (Box 1 of 4)
3)  Remove the six bolts from the driveshaft flange.
Disconnect and support the front driveshaft.
Subframe RS176742B
Box RS66501B-4 (Box 4 of 4)
4)  Disconnect the vent hose from the axle housing. See
Illustration 12
Diff Drop Brackets RS176745B
5)  Support the front differential assembly with a floor
jack.
Skid Plate RS176747B
6)  Remove the front differential assembly aft mounting
bolt. See Illustration 12.
Hardware from Sub Assy RS860783
7)  Remove the differential assembly passenger side
mounting bolt. Take care that flag-nut does not damage metal
transmission lines.
Hardware from Sub Assy RS860506
Hardware from Sub Assy RS860784
1)  If applicable, cut the driver side corner off the steering
rack skid plate and de-bur cut edge. Reinstall using OE
hardware. See Illustration 13.
8)  Pushing up on the right side of the right axle housing,
remove the driver side mounting bolt.
9
WARNING: Do not use a flame cutter or torch to
remove bracket. You could warp, weaken or damage
the bracket without the damage being visible to you,
resulting in loss of vehicle control and an accident.
2.5”
1.5”
Driver Side
Illustration 13
2)  Install skid plate RS176747B to the bottom of
subframe RS176742B using 10MM hardware from RS860506.
Torque to 45 ft. lbs. See Illustration 14.
Modified Bracket
Illustration 16
5)  Loosely attach diff drop brackets RS176745B to the
front differential upper and passenger side frame brackets with
the original hardware. See Illustration 17 and Illustration 18.
RS176742B
RS176747B
Illustration 14
3)  Draw a line, perpendicular to the bottom edge and ½”
from the edge of the slotted hole, on the front and back of the
driver side crossmember bracket. Connect the lines on the top
of the bracket providing a minimum of 5” clearance. See
Illustration 15.
RS176745B
Illustration 17
5”
Minimum
RS176745B
1/2”
Illustration 15
FRONT
4)  Using a die grinder and Sawzall follow the line and cut
off the crossmember bracket rounding off any sharp corners.
Paint bare metal to prevent rust. See Illustration 16.
Illustration 18
10
7)  With the help of an assistant, carefully raise the front
differential assembly up into the left and right drop brackets.
Loosely attach the differential assembly to the brackets with
the hardware from kit RS860783.
1)  Align index marks on front driveshaft, insert spacer
RS176586 between driveshaft and pinion flange. Secure
together with 12pt 10mm hardware from kit RS860785 using
OE torque plates. Tighten bolts to 41 ft. lbs. See Illustration 20.
Use of blue thread lock is recommended but not included.
8)  With the help of an assistant, raise subframe
RS176742B into the lower control arm frame brackets and aft
diff mount. Attach sub frame to the lower control arm brackets
with original hardware.
Torque Plate
9)  Attach aft differential mount to subframe RS176742B
with 14mm hardware from kit RS860783. Refer to Illustration
19.
RS176586
Aft Differential Mount
Index Marks
Illustration 20
SHOCK ABSORBER SPACER INSTALLATION
RS176742B
Box RS886520
Shock Spacers RS176750B
Illustration 19
Hardware from Sub Assy RS860746
CAUTION: With sub frame in place, verify that the differential
lower mount does not contact the modified frame bracket.
There must be a minimum of ¼” clearance between frame and
differential. Contact may cause vibration.
1)  Using OE nuts, install shock spacer RS176750B onto
OE shock absorber. Tighten to 30 ft. lbs. Illustration 21.
10)  Tighten the following bolts in order: Subframe
RS176742B to frame bolts to 258 ft. lbs.; the differential aft
mounting bolt to 85 ft. lbs., and the differential drop bracket
bolts to 85 ft. lbs.
OE Hardware
RS176750B
11)  Apply grease or anti-seize (not included) to the
threads of cam bolts RS176311 (4) from kit RS860784.
12)  Loosely attach the lower control arm to the subframe
with the lubricated cam bolts and hardware from kit RS860784.
Insert front alignment cam bolts, insert from front to rear. Rear
cam bolts, insert from rear to front. Align cams straight up.
OE Shock
CAUTION: Do not get grease or anti-seize on cam or subframe where cam seats.
Illustration 21
NOTES: Do not tighten the lower control arm bolts until the
vehicle is at normal ride height.
2)  Insert the absorber and spacer assembly into the
upper frame mount. Loosely install with nuts and washers from
hardware kit RS860746. See Illustration 21 and Illustration 22.
FRONT DRIVESHAFT SPACER INSTALLATION
3)  Attach the shock absorber to the lower control arm
with the original hardware. Tighten lower mounting bolts to 66
ft. lbs. Tighten Upper spacer bolts to 30 ft. lbs. See Illustration
22.
Box RS66501B-4 (Box 4 of 4)
Driveshaft Spacer RS176786
Hardware from Sub Assy RS860785
11
4)
RS176750B
 Install knuckle on vehicle:
 Carefully insert the axle into the hub until the threads
protrude from hub bearing. See Illustration 24
 Insert lower ball joint stud into steering knuckle and
loosely attach with OE nut.
 Insert upper ball joint stud into steering knuckle and
loosely attach with OE nut.
 Pull, wiggle and turn axle to seat fully in hub bearing.
See Illustration 24
OE Shock
Hub
Lower Control Arm
Illustration 22
STEERING KNUCKLE INSTALLATION
Box RS66501B-2 (Box 2 of 4)
Bearing
Left Steering Knuckle RS176743
Box RS66501B-3 (Box 3 of 4)
Axle
Right Steering Knuckle RS176744
Illustration 24
1)  Remove the integrated wheel end and wheel hub from
the passenger side steering knuckle. See Illustration 23.
Note: The axle splines must line up with the integrated wheel
end. Do not force axle in. You may need to separate upper ball
joint and turn axle or integrated wheel end, then repeat step 4.
CAUTION: Do not damage the O-ring on the wheel hub.
Steering Knuckle
Do not move on to next step until axle is seated in bearing.
Integrated Wheel End
5)  Tighten the lower ball joint stud nut to 111 ft. lbs. and
the upper nut to 85 ft. lbs.
6)  Install the axle half shaft nut. Tighten the nut to 20 ft.
lbs. Install the axle cap.
7)  Loosen the jam nut on the tie rod and thread the tie
rod end out approximately 7 3/4 turns. Insert the tie rod end
from the top into the steering knuckle and install the original
nut. Tighten the ball stud nut to 85 ft. lbs. and the jam nut to 76
ft. lbs.
O-Ring
Wheel Hub
Illustration 23
8)  Repeat steps 1 through 9 for the driver side using left
Rancho knuckle RS176743.
2)  Align the ABS sensor hole to the top of the knuckle
and attach the wheel hub to right Rancho knuckle RS176744
with the original bolts. Tighten the bolts to 129 ft. lbs.
CALIPER AND BRAKE HOSE DROP BRACKET INSTALLATION
3)  Align vacuum port upward and attach the integrated
wheel end to the knuckle with the original hardware. Tighten
the bolts to 11 ft. lbs.
Box RS66501B-4 (Box 4 of 4)
Front Brake line Brackets RS176780
Hardware from Sub Assy RS860786
Wire Ties from RS1900-12
1)  Re attach the ABS sensor to the wheel hub and the
vacuum hose to the integrated wheel end.
12
VENT HOSE EXTENSION INSTALLATION
2)  Attach the dust shield with the original hardware.
Tighten the bolts to 12 ft. lbs.
Box RS66501B-4 (Box 4 of 4)
3)  Install the right brake rotor on the passenger side
wheel hub.
Hardware from Sub Assy RS860749
4)  Install the brake caliper over the rotor. Attach the
caliper to the knuckle with the original anchor bolts. Tighten the
bolts to 175 ft. lbs. Refer back to Illustration 1 and Illustration 2.
1)
 Insert tube fitting into rubber tube from kit RS860749.
2)
 Insert other end of tube fitting in OE vent hose.
3)  Install lengthened vent hose on differential in OE
location. See Illustration 26
5)  Using the original bolt and location, attach brake hose
drop bracket RS176780 to the frame rail. Tighten bolt securely.
OE Vent Hose
6)  Carefully re-shape metal brake lines and attach OE
brake hose bracket to drop bracket RS176780 with hardware
from kit RS860786. See Illustration 25.
Tube Fitting
Rubber Tube
Wire Tie
Front Differential
Illustration 26
SWAY BAR INSTALLATION
Box RS66501B-4 (Box 4 of 4)
Sway Bar Drop Brackets RS176746B
RS176780
Hardware from Sub Assy RS860506
1)  Attach sway bar drop brackets RS176746B to the
frame with the original hardware. Tighten the nuts to 35 ft. lbs.
Wire Ties
2)  Attach the sway bar to the drop brackets with 10MM
hardware from kit RS860506. Torque to 35 ft. lbs. See
Illustration 27.
RS176746B
Illustration 25
7)  Reattach the vacuum line clips to brake line brackets.
Reposition line on clips if needed.
8)  Use wire ties from RS1900-12 to attach ABS wire to
brake line and upper OE mount. Attach ABS wire and vacuum
line to frame at upper control arm mount with wire ties. See
Illustration 25.
9)
Sway Bar
Illustration 27
 Repeat for other side.
3)  Attach the sway bar end links to the sway bar. Tighten
the nuts to 59 ft. lbs.
10)  Turn the front wheels completely left then right. Verify
adequate, ABS, brake, and vacuum line clearance and length.
13
Aft Brace Bracket RS176160 (2)
1/2-13 X 4 (2)
Subframe
RS176742B
1/2-13 X 1 (2)
-USE THREAD LOCKSleeve RS420072 (4)
Nut Bracket
RS176137 (2)
Aft Brace
RS176222B (2)
Bushing RS520041 (8)
1/2-13 X 1 (2)
-USE THREAD LOCK1/2-13 X 4 (2)
Aft Brace Bracket RS176160 (2)
Illustration 28
RS520041 and one sleeve RS420072 from kit RS860474.
Press the bushings and sleeve into aft brace RS176222B as
shown in Illustration 28.
AFT BRACE INSTALLATION
Box RS66501B-4 (Box 4 of 4)
3)  Repeat step 2 to install the rest of the bushings and
sleeves.
Aft Brace Brackets RS176160B
4)  Loosely attach two aft brace brackets RS176160 to
subframe RS176742B with the hardware from kit RS860789
Use washer against bracket only. Use thread-lock.
Aft Braces RS176222B
Hardware from Sub Assy RS860474
Hardware from Sub Assy RS860789
5)  Insert nut brackets RS176137 inside the cross
member as shown in Illustration 28. Align nut brackets over
the existing holes.
1)  Remove transfer case skid plate and trim as shown in
Illustration 29.
6)  Loosely attach two aft brace brackets RS176160 to
cross member by threading the 1.00” bolts with washers from
kit RS860474 the bolt into the nut bracket. Use thread-lock.
3.00”
FRONT
7)  Attach the aft braces to the installed brackets with the
hardware from kit RS860474. See Illustration 28.
2.75”
8)  Tighten the aft brace mounting bolts to 80 ft. lbs. then
the bracket to cross member and bracket to subframe bolts to
65 ft. lbs.
RS176160
9)  Re-install transfer case skid plate and torque to 25 ft.
lbs.
Transfer Case Skid Plate
Illustration 29
2)
 Using a silicon spray, lubricate two bushings
14
10)  Install front wheels and turn the front wheels
completely left then right. Verify adequate tire, wheel, and
ABS, brake, and vacuum line clearance and length.
LEAF SPACER AND RISER BLOCK INSTALLATION
Box RS66501B-4 (Box 4 of 4)
11)  Lower vehicle to ground. Tighten the lug nuts to 150 ft. lbs.
Riser Blocks RS15104
12)  Align the cam bolts in the center and tighten the lower
control arm pivot nuts to 240 ft. lbs.
Leaf Spacer, .250” RS176749
U-Bolts RS740017
NOTE: If full torque cannot be achieved with vehicle at ride
height, tighten cam bolts as much as possible on ground to
lock bushing and alignment in place, then raise front of vehicle
onto jack stands to apply final torque.
Hardware from Sub Assy RS860152
1)
 Support the rear axle assembly with a floor jack.
2)  Remove both rear shock absorbers. Do not reuse
OEM shock absorbers.
WARNING: Failure to fully torque lower control
arm cam bolts can cause a sudden and unexpected
change of vehicle alignment, resulting in loss of
vehicle control and an accident.
3)
 Loosen the U-bolt nuts on both sides of the vehicle.
4)  Remove the passenger side U-bolts only. Carefully
lower the rear axle and remove the original riser block. See
Illustration 31
REAR SUSPENSION
VEHICLE PREPARATION
1)  Chock front wheels. Raise the rear of the vehicle and
support the frame with jack stands. Remove the rear wheels.
2)  On the driver side, separate the parking brake cable
bracket from the bottom of the leaf spring mount. See
Illustration 30.
Illustration 31
WARNING: Do not allow the axle to hang by any
hoses or ABS cables. You could damage the hoses
or ABS cables, without this damage being visible to
you, resulting in sudden and unexpected failure of a
hose or ABS system, and an accident.
Parking Brake Cable Bracket
Illustration 30
5)  Clamp the spring assembly securely together with two
C-clamps as shown in Illustration 32.
3)  Remove the brake hose bracket from the inside of the
driver side frame rail. Disconnect plastic clips holding brake
line and wire harness to inside of frame rail. See Illustration 34.
6)  Loosen the nuts and remove the center bolts. If
necessary, hold the head of the center bolt with locking pliers.
15
8)  Place the spacer RS176749 under the spring pack
and reinstall the center bolts. Torque to 65 ft. lbs. Remove Cclamps. See Illustration 32.
Center Bolts
Helper Spring
Illustration 32
Spacer
RS176749
9)  Place riser block RS15104 on the axle pad. Loosely
attach the leaf spring to the axle with U-bolts RS740017 and
the hardware from kit 860152. See Illustration 33
RS176314
FRONT
Illustration 34
10)  Repeat steps 4 and 5 for the driver side.
3)  Attach parking-brake cable drop RS176748 to the leaf
spring mount using OE bolt and hardware from kit RS860787.
11)  Cross tighten all U-bolt nuts evenly to 85 ft. lbs.
4)  Attach original parking brake cable bracket to
RS176748 using 8mm hardware from kit RS860787. Tighten
the bolt to 12 ft. lbs.
FRONT
RS176748
Illustration 33
12)  Install new Rancho shock absorbers and torque to 66
ft. lbs.. Refer back to Important Note B.
DRIVESHAFT SPACER INSTALLATION
Box RS66501B-4 (Box 4 of 4)
BRAKE DROP BRACKETS INSTALLATION
Box RS66501B-4 (Box 4 of 4)
Sub Assy RS860731
Rear Brake Hose Drop Bracket RS176314
Rear Driveshaft Spacer RS176691
Parking Brake Cable Drop Bracket RS176748
Hardware from Sub Assy RS860732
1)  Measure pull-out of rear output shaft slip joint. If pullout exceeds 1¼” follow steps 2-5 to install rear driveshaft
spacer RS176691. See Illustration 35.
Hardware from Sub Assy RS860787
1)  Attach rear brake hose drop bracket RS176314 to the
frame with the original bolt Tighten the bolt to 12 ft. lbs. See
Illustration 34.
2)  Attach the original brake hose bracket to drop bracket
RS176314 with the 8mm hardware from kit RS860787. Insert
plastic clip on wire harness back into frame.
16
FINAL CHECKS & ADJUSTMENTS
1)  Turn the front wheels completely left then right. Verify
adequate tire, wheel, and brake hose clearance. Inspect
steering and suspension for tightness and proper operation.
Measure
2)  With the suspension at maximum extension (full
droop), inspect and rotate all axles and drive shafts. Check for
binding and proper slip yoke insertion. The slip yoke should be
inserted a minimum of one inch into the transfer case and/or
transmission.
Rear Output Shaft
3)  Ensure that the vehicle steering and brake systems
operate correctly.
Illustration 35
2)  Index-mark the rear driveshaft flange to the rear
differential pinion flange.
4)  Readjust headlamps. Have vehicle Aligned at a
certified alignment facility.
Recommended Alignment Specifications
3)
Caster (degrees): 3.60° ± 1.00°
 Support rear driveshaft with floor jack.
4)  Remove rear driveshaft flange to the rear differential
pinion flange mounting bolts
Camber (degrees): -0.10° ± 0.75°
Sum Toe In (degrees): 0.2° ± 0.2° or 0.10” ± 0.10”
5)  Align index marks on rear driveshaft, insert rear
driveshaft spacer RS176691 between driveshaft and pinion
flange. Secure together with 12mm hardware from kit
RS860732. Tighten bolts to 75 ft. lbs. See Illustration 36. Use
of blue thread lock is recommended but not included.
5)  Park the vehicle on a level surface Measure and
record the distance from the center of each wheel to the top of
the fender opening. See Illustration 37 and Illustration 3.
Record these measurements in the space provided below.
RS176691
Illustration 36
6)
 Install rear wheels.
7)
 Lower vehicle to ground. Tighten the lug nuts to 150 ft. lbs.
Illustration 37
17
Torque Specs
Front Components
Skid Plate RS176747B
Subframe RS176742B to Frame
Lower Control Arm to Subframe RS176742B
Differential Aft Mount to Subframe RS176742B
Differential Drop Bracket RS176745B
Driveshaft to Pinion Flange
Shock Mount, Upper
Shock Mount, Lower
Shock Spacer RS176750B
Wheel Hub to Steering Knuckle
Integrated Wheel End to Hub
Lower Ball Joint
Upper Ball Joint
Tie Rod End Ball Stud
Tie Rod Jam Nut
Axle Shaft
Dust Shield to Steering Knuckle
Brake Caliper to Steering Knuckle
Brake Line Bracket
Sway Bar Drop Bracket RS176746B
Sway Bar End Link
Aft Brace Brackets
Aft Brace to Brackets
Wheel Lug Nuts
Rear Components
Brake Hose Drop Bracket RS176314
Parking-Brake Cable Drop Bracket RS176748
Driveshaft to Pinion Flange
Leaf Spring Center Bolts
Leaf Spring U-bolt
Shock Absorbers
Wheel Lug Nuts
45 ft. lbs
258 ft. lbs.
240 ft. lbs.
85 ft. lbs.
85 ft. lbs.
41 ft. lbs.
30 ft. lbs.
66 ft. lbs.
30 ft. lbs.
129 ft. lbs.
11 ft. lbs.
111 ft. lbs.
85 ft. lbs.
85 ft. lbs.
76 ft. lbs.
20 ft. lbs.
12 ft. lbs.
175 ft. lbs.
12 ft. lbs.
35 ft. lbs.
59 ft. lbs.
65 ft. lbs.
80 ft. lbs.
150 ft. lbs
18
12 ft. lbs.
12 ft. lbs.
75 ft. lbs.
65 ft. lbs.
85 ft. lbs.
66 ft. lbs.
150 ft. lbs
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